Building block and extreme weather building system

ABSTRACT

The present invention relates to the reuse of otherwise discarded plastic to be used as building material and is resistant to extreme weather conditions. A building block comprises a multiple sided hollow box, wherein the sides of the box are tapered, with at least one keyway respectively slotted on at least two faces of the hollow box and an interlocking key which has a corresponding shape with the keyway to tightly interlock in the keyway.

FIELD OF THE INVENTION

The present invention relates to a building block and a building system suitable for extreme weather using the building block.

BACKGROUND TO THE INVENTION

Often found in developing countries are buildings that are unsuitable for extreme weather conditions. Major catastrophes can occur, and earthquakes, hurricanes, tornadoes, floods, and fire are not uncommon, the effect being devastating. Increasing building density using waste plastic as a form work for locally attained material is efficient and economical.

On the other hand, waste plastics has become a major contributor to pollution in the sea and this building system is a reasonable way to transform the locally available waste plastic materials to a durable construction unit. Furthermore, fire safe building materials are in large need in the building industry.

OBJECT OF THE INVENTION

The object of this invention is to provide system and method of to meet the above needs or at least to provide the public with a useful alternative.

It should be noted that any one of the aspects mentioned above may include any of the features of any of the other aspects mentioned above and may include any of the features of any of the embodiments described below as appropriate.

SUMMARY OF THE INVENTION

In a first aspect of the invention there is proposed a building block comprising a multiple sided hollow box, wherein the ends of the box are tapered, with at least one keyway respectively slotted on at least two faces of the hollow box; an interlocking key which has a corresponding shape with the keyway to be tightly interlocked in the keyway.

In preference at least one of the top or bottom face of the block is open.

In preference the left and right face of the box are tapered typically at 10° degrees.

In preference there are two keyways respectively slotted on each of the front face, rear face, left face and right face.

In preference each box is filled with locally available material, such as but not limited to, earth, sand, gravel, mud, and concrete.

In preference the weight of the infill material provides sufficient resistance to wind forces.

In preference an aperture is adapted to be used for reinforcement or a passageway for members in each face where there is the keyway.

In a further form of the invention there is proposed a building system for extreme weather, comprising building blocks and interlocking keys as described above.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will refer to a number of drawings and tables as follows.

FIG. 1 are structural calculations for wind loading according to US standards;

FIGS. 2A-2C are structural calculation for maximum deflections on several different wall heights according to US standards;

FIG. 3 is a table of properties for different polymers;

FIGS. 4A-4C provide the dimensions and the general assembly according to an embodiment of the present invention;

FIGS. 5A-6B illustrate the foundation designs according to embodiments of the present invention;

FIGS. 7A-7C illustrate typical wall designs according to embodiments of the present invention; and

FIGS. 8A-8B illustrate roof designs according to embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description of the invention refers to the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts. Dimensions of certain parts shown in the drawings may have been modified and/or exaggerated for the purposes of clarity or illustration.

The first three Figures relate to calculations in relation to the use of the building blocks the subject of the present application.

Referring to FIGS. 4A-4C, an embodiment of the present invention provides a building block 10 which is used for building a wall suitable for extreme weather by aligning one with another.

The building block 10 consists of a multiple-sided hollow box, could be four or five sides. In an embodiment there are four sides include a front face, rear face, left face, right face. In another embodiment there are five sides, including front face, rear face, left face, right face and bottom face as illustrated in FIG. 4A. However, the block does not have to have a bottom face and could be open.

The box size varies in accordance with general building expectations in the region of construction. The box is manufactured at least in part from waste plastic with inclusions of lime, ceramic dust and or other material to become a fire safe building material. The box sizes may vary between 500 mm×250 mm×250 mm to 12″×12″×12″. The box is generally of an isosceles trapezium shape with the left and right faces or sides tapered at an angle to the front and rear faces or sides. The taper angle is typically tapered around 10° degrees but that may vary and the sides each include at least one and preferably two keyways 16. Whilst there are illustrated keyways on each of the sides, in the case of a straight wall they may only be needed on the left face and the right face. Interlocking hermaphrodite keys 20 in the 250 mm×250 mm faces are tightly interlocked in the two keyways 16 which are aligned vertically as shown in FIG. 4B and aligned in parallel as illustrated in FIG. 4C. There may also be two keyways 16 slotted on the front face and the rear face of the box.

Preferably, an aperture or knockout 12 adapted to be used for reinforcement or a passageway for members such as metal reinforcing rods, electrical conduits and/or plumbing is provided in each face or in the face where there is at least a keyway 16. However, it may only be present in two faces to allow for the members to enter into and out of a block. The taper in the blocks 10 allows for building of curved as shown in FIGS. 7A-7C and 8A and/or straight walls in FIGS. 6A-6B and 8B. Blocks are placed in alternate orientations to make a straight wall as shown in FIGS. 5A, 6A-6B, 8B. Alternatively, the blocks 10 are placed without alternate orientation for curved as shown in FIGS. 7A-7B, 8A or serpentine walls as shown in FIG. 7C.

The top of each block 10 is open and the top of a block 10 interlocks with the base of another block 10 in the row above through the interlocking hermaphrodite keys 20 as illustrated in FIG. 4B. Preferably, to facilitate the alignment of a top and a bottom block 10, the top surface of the block 10 is raised up while the bottom surface of the block 10 is caved in as shown in FIG. 4B. Accordingly, there are two inverted triangular grooves 18 respectively located at the front face and rear face of the block 10. As such, when the top block 10 is interlocked with the bottom block 10, the top part of the bottom block will be engaging with the concave part of the top block.

In one embodiment, if the groove 18 of a bottom block forms a substantially right angle with slight taper press with the concave part of a top block, then the top block can be simply pushed on the bottom one to be aligned. In another embodiment, the groove 18 of a bottom block forms an inverted acute angle, then the top block engages with the bottom one by sliding the concave part of the top block over the raised part of the bottom block.

FIGS. 5A-6B illustrate the foundation designs according to embodiments of the present invention. FIGS. 7A-7C illustrate typical wall designs according to embodiments of the present invention. FIGS. 8A-8B illustrate roof designs according to embodiments of the present invention.

Each box of the blocks 10 provided by the present invention is filled with locally available material, earth, sand, gravel, mud, concrete, etc. the weight of the infill material providing sufficient resistance to wind forces. Additional reinforcement maybe inserted through the blocks and can be post tensioned to further strengthen the assembly.

The foundation and floor are assembled with blocks side to side and end to end and may be tensioned with reinforcement. The blocks are filled with earth and the top finished with preferred material (concrete, wood, tile or other).

The roof has blocks laid perpendicular to the walls, flat on a slope for water drain, or as an arch or combinations of both. And may be tensioned with reinforcement.

Each block may be finished with a texture (stucco, plain, vertical slat, horizontal slat). There is a ½ block for stagger laying in sequence and an end cap for each row to conceal tensioning reinforcement.

It can be understood that the number of the keyway 16 could be one or three or even more.

It can also be understood that the length of the Interlocking hermaphrodite keys 20 could be the same as or shorter or longer than the height of a block 10, as long as it will provide sufficient interlocking connection between the aligned keyways 16.

The present invention further provides a building system for extreme weather which comprises building blocks and interlocking hermaphrodite keys as described in the above embodiments.

The reader will now appreciate the present invention which provides an improved building block.

LIST OF COMPONENTS

10 block

12 aperture

14 end

16 keyway

18 groove

20 key

The reader will now appreciate the present invention which provides an improved Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims to embrace any and all equivalent devices and apparatus. Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of the common general knowledge in this field.

In the present specification and claims (if any), the word “comprising” and its derivatives including “comprises” and “comprise” include each of the stated integers but does not exclude the inclusion of one or more further integers. 

1. A building block comprising: a multiple sided hollow box, wherein ends of the box are tapered; at least one keyway respectively slotted on at least two faces of the hollow box; and an interlocking key which has a corresponding shape with the at least one keyway to be tightly interlocked in the at least one keyway.
 2. The block of claim 1 wherein at least one of a top face or a bottom face of the block s open.
 3. The block of claim 1 wherein a left face and a right face of the box are tapered at an angle of about 10° degrees.
 4. The block of claim 1 wherein the at least one keyway comprises two keyways respectively slotted on each of a front face, a rear face, a left face and a right face of the box.
 5. The block of claim 1 wherein the box is filled with locally available infill material, but not limited to earth, sand, gravel, mud, and concrete.
 6. The block of claim 5 wherein the weight of the infill material provides sufficient resistance to wind forces.
 7. The block of claim 1 further comprising an aperture adapted to be used for reinforcement or a passageway for members in each face where there is the at least one keyway.
 8. A building system for extreme weather, comprising building blocks and interlocking keys as defined in claim
 1. 